US10695888B2 - Elastic biasing element and encoder arrangement for precise control of force or torque - Google Patents

Elastic biasing element and encoder arrangement for precise control of force or torque Download PDF

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US10695888B2
US10695888B2 US15/508,711 US201515508711A US10695888B2 US 10695888 B2 US10695888 B2 US 10695888B2 US 201515508711 A US201515508711 A US 201515508711A US 10695888 B2 US10695888 B2 US 10695888B2
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feed
force
biasing element
drive
feed system
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US20170282330A1 (en
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John Harte
Daniel R. Cloutier
Mark Maichel
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Sunnen Products Co
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Sunnen Products Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
    • B24B49/16—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation taking regard of the load
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B33/00—Honing machines or devices; Accessories therefor
    • B24B33/02—Honing machines or devices; Accessories therefor designed for working internal surfaces of revolution, e.g. of cylindrical or conical shapes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B33/00—Honing machines or devices; Accessories therefor
    • B24B33/08—Honing tools
    • B24B33/087—Honing tools provided with measuring equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B47/00—Drives or gearings; Equipment therefor
    • B24B47/20—Drives or gearings; Equipment therefor relating to feed movement

Definitions

  • This invention relates generally to an apparatus, system, and method using an elastic biasing element in combination with an encoder arrangement for precise control of force or torque applied to a moving object, and more particularly, for precisely controlling force or torque applied for controlling feed force of a bore finishing tool such as a honing tool.
  • a finishing tool assembly In the context of bore finishing, such as, but not limited to, honing, a finishing tool assembly will be rotated within a bore or other cavity of a workpiece, about an axis and reciprocatingly moved or stroked along the axis, while a feed force is applied radially or laterally to an abrasive element or elements, e.g., honing stone or stones, for abrading material from the surface of the workpiece within the bore or cavity.
  • This feed force is applied by a feed mechanism or system which typically includes one or more feed elements within the tool, e.g., wedge or wedges of the finishing tool assembly.
  • the feed force is applied by an output rod of the feed mechanism axially against the wedge or wedges, which translate the axial force into radial outward force applied to the honing stone or stones.
  • the applied force is typically precise, but can be intentionally varied as required for imparting certain precise characteristics to the surface of the workpiece bore or cavity.
  • the workpiece bore or cavity may originally have a shape such as a barrel, hourglass or taper, and it may be sought to remove that original shape and impart a very precise cylindrical shape to the surface.
  • the original bore may also skew, or have other malformations that are required to be removed by the honing or other bore finishing operation. Conversely, it may be desired to impart a precise taper, hourglass, or barrel shape.
  • the feed force can thus desirably be sought to be a precisely controlled constant force, or a precisely controlled variable force, e.g., controlled to virtually any required function or algorithm, for instance, based on time, position, or other variables that are monitored by the control system controlling operation of the feed mechanism.
  • feed force is generated using drive apparatus of the feed system, such as a servomotor, controlled by a motion control system capable of responding to externally measured or computed digital signals.
  • Some mechanism is used to convert the motor rotation to linear motion.
  • the mechanism can be a ball screw and ball nut, a rack and pinion, or any other device capable of converting rotary motion to linear motion.
  • the ball nut moving linearly, pushes against a spring which in turn bears against the output rod.
  • An alternative is a linear actuator, cylinder, or the like, can be used.
  • a problem that can occur when operating less complex and costly feed systems when attempting to apply precise feed force, whether constant or varied in a controlled manner, is that as the tool encounters obstacles, irregularities, bore size variances, such as a narrower bore section, surface skew, or the like, rigidity of the feed mechanism can cause a feed force spike if the feed force is not sufficiently quickly adjusted or attenuated. This is problematic as feed and motion control systems always require some amount of time to react to sudden changes and in that amount of time the force will continue to increase which can result in variations, longer process times, and other shortcomings or problems.
  • What is disclosed is apparatus, system, and method using an elastic biasing element in combination with an encoder arrangement for precise control of force or torque applied to a moving object, and more particularly, incorporated into a feed control system for bore finishing such as honing, for precisely controlling force or torque, for instance, applied for controlling feed force of a bore finishing tool such as a honing tool, to substantially reduce or eliminate the above referenced problems and shortcomings of known systems, with minimal complexity and cost compared to more sophisticated known systems.
  • a feed system for a feeding and applying a feed force to an abrasive element of a bore finishing tool in a lateral direction relative to an axis of rotation thereof comprises:
  • a drive apparatus controllably operable to move a drive element in a first direction and an opposite second direction within a predetermined range
  • an elastic biasing element having a first end and a second end, the first end disposed in predetermined relation to the drive element and configured so as to be displaced by the movement thereof to cause the biasing element to elastically store a quantity of energy proportional to the displacement and representative of the feed force, and the second end being disposed in predetermined relation to an output element disposed to move generally axially in cooperation with a feed element of the bore finishing tool to transfer and apply the feed force laterally to the abrasive element and to communicate or transfer changes in the applied feed force from the abrasive element to the second end of the biasing element to cause joint movement or displacement thereof;
  • a first sensor positioned and operable to determine a value representative of the movement or displacement of the second end of the biasing element or output element and output a signal representative thereof
  • a second sensor positioned and operable to determine a value representative of the displacement of the first end of the biasing element or position of the drive element and output a signal representative thereof
  • a processor connected to the first sensor and to the second sensor to receive the signals outputted thereby and operable to responsively determine a value for the movement of the drive element of the drive apparatus to apply a selected feed force.
  • the selected feed force can have a precise constant value.
  • the feed force can be controlled to any required function, either based on time, position or other variables that are monitored by the control system.
  • the drive apparatus comprises a servomotor or such controlled by a motion control system capable of responding to externally measured or computed digital signals. Some means is used to convert the motor rotation to linear motion. This can be accomplished in a suitable, as a non-limiting example, using a ball screw and ball nut, a rack and pinion, or any other device capable of converting rotary motion to linear motion.
  • the ball nut moving linearly, pushes against an elastic biasing element, which is preferably, but not limited to, a spring or springs which in turn bear against an output element such as an output rod.
  • the drive apparatus/element can comprise a fluid cylinder such as a hydraulic cylinder, or a linear motor or actuator so that conversion of rotary to linear motion is not required.
  • the bore finishing tool can be a honing tool, wherein the output element is typically a rod configured to drive a feed element of the tool, e.g., a wedge, to translate and apply the feed force laterally to an abrasive element(s) or stone(s), as the tool assembly is rotated and stroked by the honing machine relative to some workpiece that has a bore to be finished.
  • the output element is typically a rod configured to drive a feed element of the tool, e.g., a wedge, to translate and apply the feed force laterally to an abrasive element(s) or stone(s), as the tool assembly is rotated and stroked by the honing machine relative to some workpiece that has a bore to be finished.
  • the elastic biasing element or elements can be linear or nonlinear springs or other elastic components, and combinations of linear and nonlinear springs and springs having different spring constants, as long as their force vs. compression or tension function is known and can be digitally computed.
  • the first sensor can be a linear encoder and is considered to be the primary input.
  • This encoder is considered primary because it measures the position of the second end of the biasing element either directly or via measuring the position of the output element, e.g., output rod, and/or other rigid components connected to it. This position may be displayed and/or used for other machine control functions.
  • the honing cycle can be stopped when the position reaches a value known to correspond to a desired bore size.
  • the second sensor can be a secondary linear encoder could be placed directly on the drive element, e.g., ball nut, rack and pinion, etc., (or in that vicinity) to measure its position which is representative of the displacement of the first end of the biasing element.
  • servomotors will commonly be equipped with internal rotary encoders so it can be simpler to instead use that encoder as the secondary encoder.
  • the motion control system will continually sample the outputs of both the primary and secondary encoders or other sensors and compute their differences. This difference is compared to a desired difference which corresponds to a desired net level of force resulting from the overall displacement, e.g., compression of the biasing element or elements. This computed difference then becomes the feedback variable controlling the motion of the drive apparatus. If the difference is too large then the drive apparatus is controllably operated in the direction that will reduce that difference; if the difference is too small then the apparatus is controllably operated in the direction that will increase the difference. In this manner the output element or rod can be moved through a range of motion continually imparting the desired (programmed) level of force.
  • the output element encounters sudden resistance (in the honing example, when the stone contacts the workpiece bore) then there will be a force spike at impact.
  • the motion control system always requires some amount of time to react to sudden changes and in that amount of time the force will continue to increase.
  • the biasing element(s) e.g., spring(s)
  • this system can be designed to have a spring(s) with a spring constant(s) that keep those sudden force changes within a very small tolerance band as required by the particular application.
  • a drive apparatus controllably operable to move a drive element in a first direction and an opposite second direction within a predetermined range
  • an elastic biasing element having a first end and a second end, the first end disposed in predetermined relation to the drive element so as to be displaced by the movement thereof to cause the biasing element to elastically store a quantity of energy proportional to the displacement and representative of the feed force, and the second end being disposed in predetermined relation to an output element disposed to move generally axially in cooperation with a feed element of the bore finishing tool to transfer and apply the feed force laterally to the abrasive element and to move or displace as a function of changes in the applied force;
  • controlling the drive apparatus to move the drive element as required to variably displace the first end of the biasing element responsive to the movements or displacements of the second end, to apply a predetermined feed force to the abrasive element.
  • FIG. 1 is a simplified side view of a representative embodiment of a motion control system of the invention, used for controlling feed of a bore finishing tool;
  • FIG. 2 is a simplified side view of a another embodiment of a motion control system of the invention, used for controlling feed of a bore finishing tool;
  • FIG. 3 is a simplified side view of a another embodiment of a motion control system of the invention, used for controlling feed of a bore finishing tool;
  • FIG. 4 is another simplified side view of the motion control system of FIG. 3 , shown in another operating mode;
  • FIG. 5 is a graphical representation showing a relationship between encoder difference and output force for the motion control system of FIGS. 3 and 4 ;
  • FIG. 6 is a perspective view of a representative bore finish machine incorporating the invention, showing a machine controller operable to perform control aspects of the invention
  • FIG. 7 is a perspective view of aspects of the machine of FIG. 6 , including a rotary spindle carrying a tool holder on which is mounted a representative bore finishing tool which is a honing tool, along with associated workpiece holding apparatus of the machine; and
  • FIG. 8 is another perspective view of the machine, showing the spindle and tool holder.
  • a bore finishing feed system 18 incorporating an apparatus, system, and method of motion control adapted for imparting a precise feed force to an abrasive element of a tool of a bore finishing tool, is shown.
  • the feed system 18 is operable to control the applied feed force as a constant force, or a force controlled to any required function, either based on time, position or other variables that are monitored by the system, as desired or required for a particular application.
  • Input motion is accomplished with a drive apparatus 20 such as a servomotor 30 or such, having a drive element 22 , and capable of responding to externally measured or computed digital signals.
  • a drive apparatus 20 such as a servomotor 30 or such, having a drive element 22 , and capable of responding to externally measured or computed digital signals.
  • some apparatus to convert the motor rotation to linear motion 24 is required. In this embodiment this is accomplished using a ball screw 26 and a ball nut 28 , but it could be a rack and pinion or any other device capable of converting rotary motion to linear motion.
  • the ball nut 28 moving linearly, pushes against a first end 34 of an elastic biasing element 32 which in this embodiment is a spring, and which has a second end 36 that in turn bears against an output element 38 , which can comprise for instance, an output rod of the bore finishing or honing machine.
  • the output element 38 will drive a wedge 42 of a honing tool 40 .
  • the wedge 42 imparts force and motion to an abrasive element or elements 44 , such as a honing stone or stones.
  • This honing tool assembly is rotated and stroked by the honing machine (spindle not shown) relative to a workpiece 48 that has a bore surface 46 within a bore to be finished.
  • the force being delivered by the above described apparatus will cause the elastic biasing element 32 (spring) to compress by an amount that is a function of the force being applied.
  • x and y represent the linear positions of rigid components connected to ends 34 and 36 of biasing element 32
  • x 0 and y 0 are some pair of positions where the biasing element 32 is uncompressed
  • nonlinear springs or other elastic components may be used as biasing element 32 as long as their force vs. compression function is known and can be digitally computed.
  • the position x is measured continually by a primary encoder 50 , which here is a linear encoder connected to a process controller 76 of the system for outputting positional signals thereto.
  • This encoder 50 is considered primary because it measures the position of the output element 38 and other rigid components connected to it relative to a fixed location such as a frame 52 of the machine on which the system is used. It is often useful or necessary to display this position or use it for other control functions.
  • the honing cycle can be stopped when the position x reaches a value known to correspond to a desired bore size.
  • a secondary encoder 54 also connected to controller 76 for outputting positional signals thereto can be placed directly on the ball nut 28 (or in that vicinity) to measure the position y.
  • servomotors will commonly be equipped with internal rotary encoders so it becomes simpler to instead use that encoder as the secondary encoder 54 .
  • the system 18 will continually sample both the primary and secondary encoders 50 and 54 and compute their differences. This difference is compared to a desired difference which, by the functions shown above, corresponds to a desired level of feed force. This computed difference then becomes the feedback variable controlling the motion of the drive apparatus 20 . If the difference is too large then the drive apparatus 20 is operated in the direction that will reduce that difference; if the difference is too small then the apparatus 20 is operated in the direction that will increase the difference.
  • the output element 38 can be moved through a range of motion continually imparting the desired (programmed) level of feed force.
  • the output element 38 encounters sudden resistance (in the honing example, when the abrasive element or honing stone contacts the workpiece bore surface 46 ) then there will be a force spike at impact.
  • the system 18 always requires some amount of time to react to sudden changes and in that amount of time the force will continue to increase. If the elastic biasing element 32 is fairly “soft” (low value of k), then the force will increase only minimally in the brief time that the system can respond to the change in position x. Therefore this system can be designed to have a spring with a spring constant that keeps those sudden force changes within a very small tolerance band as required by the particular application.
  • drive apparatus 20 can be automatically controlled by controller 76 to move the drive element 22 as required to variably displace the first end 34 of the biasing element 32 responsive to changes in the applied feed force as represented by displacements of the second end 36 , to apply a predetermined feed force to the abrasive element 44 .
  • controller 76 can be automatically controlled by controller 76 to move the drive element 22 as required to variably displace the first end 34 of the biasing element 32 responsive to changes in the applied feed force as represented by displacements of the second end 36 , to apply a predetermined feed force to the abrasive element 44 .
  • FIGS. 1 and 2 show one simple embodiment of the system and apparatus of the invention, but many other variations are envisioned:
  • the driver could be a linear driver 56 such as a linear motor or a fluid cylinder such as a hydraulic cylinder controlled by a servo valve, which often can be supplied with embedded linear encoders. This variation is shown in FIG. 2 .
  • the same principle of operation can used to control an output torque.
  • the spring is a torsion spring.
  • the primary encoder then is a rotary encoder. Again the difference between the two rotary encoders represents some level of torque as determined by the spring constant of the torsion spring.
  • the spring need not be a conventional coil spring. It can be any component that is significantly less rigid than the rest of the drive train.
  • the spring can be one capable of tension so that a pulling force can be controlled, or both compression and tensions springs may be used in combination to have a system capable of pushing and pulling.
  • this elastic component may be multiple springs arranged in an assembly so that push and pull forces can be controlled with the same device.
  • the elastic component may be an assembly of multiple springs with various spring constants, to provide finer force control for lower levels of force than for higher levels of force, thereby keeping the overall length of the device to a minimum.
  • non-linear springs may be used to achieve the same effect.
  • each set is comprised of a subset of springs of various strengths, each subset acting in series, but nested together to optimize the utilization of space.
  • Each subset is comprised of multiple springs in parallel, which allows for achieving the low spring rate (for better control) also in a relatively small space.
  • FIG. 3 shows an assembly that is being pushed by the ball screw and motor.
  • a push-side spring Set 64 is partially compressed to deliver a push force F through a central feed rod that comprises the output element 38 (in connection with the feed element of the tool such as wedge 42 ( FIGS. 1 and 2 ).
  • the other set of springs is a pull-side set 62 which is relaxed and not used.
  • FIG. 4 shows an assembly that is being pulled by the ball screw and motor arrangement.
  • the pull-side spring set 62 is partially compressed, delivering a force to the opposite side of a flange on the feed rod so that it will provide a pulling force F on the other end of the feed rod acting as output element 38 in connection with the wedge or other feed element of the associated tool (see FIGS. 1 and 2 ), the force F comprising the feed force in both instances.
  • FIG. 4 also illustrates a locking cylinder or mechanism 72 (pneumatic or hydraulic) which can engage a locking notch 74 in the feed rod. If the system is placed in a neutral position (both spring sets relaxed) then this mechanism 72 can lock in the notch 74 which will lock the entire feed system. When locked, neither set of springs are used and the motion of the servomotor 30 will result in direct motion of the feed rod with no control of feed force. This feature mimics the behavior of older honing machine feed systems and is still useful for some honing applications.
  • FIGS. 3 and 4 employ springs of various strengths in series to create a non-linear (or piece-wise linear) relationship between the measured difference in encoder positions and the force being applied.
  • FIG. 5 is a graph showing this relationship between encoder difference and output force.
  • a non-linear spring could be designed and employed as elastic biasing element 32 .
  • a well-known way to achieve that is with a coil spring wound to have a continuously varying pitch.
  • a special spring of that type could be produced to give nearly the same curve as shown as shown in FIG. 5 . and hence the same benefit.
  • this above described apparatus and system can maintain the feed force very closely to the desired feed force set by the system or input by the operator. In many applications, closer control of feed force improves the bore size control of the honing operation and optimizes the life and performance of the abrasive element or honing stone.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
  • Constituent Portions Of Griding Lathes, Driving, Sensing And Control (AREA)
US15/508,711 2014-09-04 2015-09-04 Elastic biasing element and encoder arrangement for precise control of force or torque Active 2036-02-12 US10695888B2 (en)

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US15/508,711 US10695888B2 (en) 2014-09-04 2015-09-04 Elastic biasing element and encoder arrangement for precise control of force or torque

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US201462045872P 2014-09-04 2014-09-04
PCT/US2015/048710 WO2016037143A1 (en) 2014-09-04 2015-09-04 Elastic biasing element and encoder arrangement for precise control of force or torque
US15/508,711 US10695888B2 (en) 2014-09-04 2015-09-04 Elastic biasing element and encoder arrangement for precise control of force or torque

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CN105855631B (zh) * 2016-05-11 2018-02-16 广西桂冠电力股份有限公司大化水力发电总厂 灯泡贯流式水轮机主轴和转轮现场铰孔装置
DE102017117069B4 (de) * 2017-07-27 2022-07-14 Gehring Technologies Gmbh + Co. Kg Honwerkzeug und Verfahren zur Honbearbeitung
DE102017121269A1 (de) 2017-09-14 2019-03-14 Microcut Ltd. Verfahren und Vorrichtung zur Feinbearbeitung von zylindrischen Werkstückflächen
CN114833712B (zh) * 2022-04-18 2023-03-21 南京航空航天大学 一种实时调节珩磨压力的控制系统及其运行工艺

Citations (7)

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DE3537172A1 (de) * 1985-10-18 1987-04-23 Audi Ag Verfahren zum bearbeiten einer bohrung sowie vorrichtung zur durchfuehrung des verfahrens
US5095662A (en) * 1989-04-01 1992-03-17 Maschinenfabrik Gehring Gmbh & Co. Process for honing bores and a honing machine for performing the process
US5269103A (en) * 1990-08-04 1993-12-14 Nagel Maschinen-Und Werkzeugfabrik Gmbh Honing measuring tool
US5433656A (en) 1993-04-14 1995-07-18 Sunnen Products Company Linkage controlled spring powered feed system
US20070298685A1 (en) 2004-09-07 2007-12-27 Sunnen Products Company Honing Feed System Having Full Control of Feed Force, Rate, and Position and Method of Operation of the Same
US8277280B2 (en) 2004-09-07 2012-10-02 Sunnen Products Company Honing feed system and method employing rapid tool advancement and feed force signal conditioning
US20130178138A1 (en) 2010-09-21 2013-07-11 Sunnen Products Company Honing tool holder with integral in-process feed system

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3537172A1 (de) * 1985-10-18 1987-04-23 Audi Ag Verfahren zum bearbeiten einer bohrung sowie vorrichtung zur durchfuehrung des verfahrens
US5095662A (en) * 1989-04-01 1992-03-17 Maschinenfabrik Gehring Gmbh & Co. Process for honing bores and a honing machine for performing the process
US5269103A (en) * 1990-08-04 1993-12-14 Nagel Maschinen-Und Werkzeugfabrik Gmbh Honing measuring tool
US5433656A (en) 1993-04-14 1995-07-18 Sunnen Products Company Linkage controlled spring powered feed system
US20070298685A1 (en) 2004-09-07 2007-12-27 Sunnen Products Company Honing Feed System Having Full Control of Feed Force, Rate, and Position and Method of Operation of the Same
US7575502B2 (en) 2004-09-07 2009-08-18 Sunnen Products Company Method of operating honing feed system having full control of feed force, rate, and position
US8277280B2 (en) 2004-09-07 2012-10-02 Sunnen Products Company Honing feed system and method employing rapid tool advancement and feed force signal conditioning
US20130178138A1 (en) 2010-09-21 2013-07-11 Sunnen Products Company Honing tool holder with integral in-process feed system

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EP3188865A4 (en) 2018-04-25
BR112017004340A2 (pt) 2017-12-05
EP3188865B1 (en) 2020-11-18
BR112017004340B1 (pt) 2022-11-16
US20170282330A1 (en) 2017-10-05
EP3188865A1 (en) 2017-07-12
WO2016037143A1 (en) 2016-03-10

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